Construction kit for making a sink and basin

Abstract

Kit (2) for the manufacture of a washbasin (1), comprising a base body (3) with a hollow (19) on its upper side, the bottom of which slopes towards a drain opening (15) formed in the hollow (19), wherein the base body (3) is made of rigid foam and is provided at least on its upward-facing surfaces with a waterproof layer (13), on which, in turn, a layer of adhesive agent (14) is disposed, in particular directly, which promotes the adhesion of thin-layer mortar or filling material, in particular concrete filler, wherein the base body comprises a plurality of cut rigid foam panels (8, 9, 10, 11) that are arranged one on top of the other and are firmly connected to each other.

Description

[0001] The present invention relates to a kit for manufacturing a washbasin, comprising a base body with a recess on its upper side, the bottom of which slopes towards a drain opening formed in the recess, wherein the base body comprises rigid foam and is provided, at least on its upper side, with an adhesion-promoting layer that promotes the adhesion of thin-bed mortar or leveling mortar, in particular concrete leveling mortar. The invention further relates to a washbasin manufactured from such a kit.

[0002] Kits for manufacturing a washbasin are generally known in the prior art. The products "LAVADO-FLOAT L" from Lux Elements GmbH & Co KG and "Sanbath" from WEDI GmbH are mentioned here as examples only. These kits comprise a base body with a recess on the upper surface, the bottom of which slopes towards a drain opening formed within the recess. The base body is made from a single block of rigid foam, in which the recess and slope are milled. With the exception of the back, the main outer surfaces are coated with a mineral layer that acts as a bonding agent, promoting the adhesion of thin-bed mortar or filler. Accordingly, the washbasins can be plastered or tiled after installation.

[0003] The publications DE 43 17 853 A1, DE 20 2008 011 165 U1 and DE 20 2010 002 332 U1 represent the state of the art.

[0004] Based on this state of the art, it is an object of the present invention to create a kit for the manufacture of a washbasin as well as a washbasin of the type mentioned above with an alternative design.

[0005] To solve this problem, the present invention provides a kit for manufacturing a washbasin, comprising a base body with a recess on its upper side, the bottom of which slopes towards a drain opening formed in the recess, wherein the base body comprises rigid foam, has a plurality of surfaces and is provided at least on its upward-facing surfaces with a waterproof layer, on which, in turn, a bonding agent layer is arranged, in particular directly, which promotes the adhesion of thin-bed mortar or filler material, in particular concrete filler, wherein the base body comprises a plurality of cut rigid foam panels which are arranged one above the other and firmly connected to each other.

[0006] A significant advantage of the kit according to the invention is that the base body is made from a plurality of pre-cut rigid foam sheets. Cutting the individual rigid foam sheets does not require a milling machine, thus avoiding machine acquisition costs if suitable cutting tools for rigid foam sheets are already available. Furthermore, the design of the base body can be highly variable thanks to the pre-cut sheets. Although rigid foam sheets are generally water-repellent, they can warp when exposed to moisture. To prevent such warping, the base body according to the invention is provided with a waterproof layer, at least on its upward-facing surfaces that will be exposed to water during subsequent use of the washbasin.On top of the waterproof layer, an adhesion-promoting layer is arranged, particularly directly, which promotes the adhesion of thin-bed mortar or filler material, especially concrete filler, in order to be able to coat the base body with filler material or cover it with tiles after its assembly, despite the waterproof layer.

[0007] Preferably, the waterproof layer is a plastic film, for example made of polyethylene.

[0008] The bonding layer is advantageously a fleece or fabric to which thin-bed mortar or filler material can adhere well.

[0009] According to one embodiment of the present invention, an adhesion promoter layer is arranged directly below and above the waterproof layer. Such a three-layer structure consisting of an adhesion promoter layer, a waterproof layer, and another adhesion promoter layer can be produced, for example, by laminating or thermally fixing a fabric or nonwoven material to both sides of a plastic film. The lower adhesion promoter layer serves to attach the waterproof layer to the base body. Thus, during the production of the top layer, the rigid foam can, for example, be foamed directly onto the adhesion promoter layer. Alternatively, bonding or fastening using a thermal process is also conceivable.

[0010] The bottom of the depression is advantageously formed by a downwardly angled section of an upper rigid foam board, in particular from the uppermost rigid foam board. This results in a simple construction.

[0011] According to one embodiment of the present invention, at least the side walls of the recess are lined with sealing film elements, which are preferably pre-cut and pre-formed. These sealing film elements are provided with an adhesive layer, at least on their outwardly facing surfaces, and preferably on both surfaces. The sealing film elements preferably have a sealing film section facing the rear of the base body, and in particular, a section that is flush with the rear of the base body. The sealing film from which the sealing film elements are made can, in turn, be a plastic film, for example, made of polyethylene. The adhesive layer is preferably formed from a woven or non-woven fabric. The sealing film section facing the rear of the base body serves to seal against a wall on which the washbasin is subsequently mounted.

[0012] Preferably, the rigid foam board forming the bottom of the recess has a thickness in the range of 2 to 10 mm, particularly in the range of 4 to 7 mm. A comparatively small board thickness is advantageous for the formation of the angled board section.

[0013] Advantageously, a rigid foam board is arranged directly below the rigid foam board forming the bottom of the recess, which has a greater thickness than the rigid foam board forming the bottom of the recess, in particular a thickness in the range of 15 to 35 mm, or better still in the range of 20 to 25 mm, wherein the rigid foam board arranged below the rigid foam board forming the bottom of the recess has a recess extending from the rear edge of the board below the angled section of the board, the width and depth of which correspond to the width and depth of the angled section of the board.

[0014] Preferably, a rigid foam plate arranged below the rigid foam plate that is arranged below the rigid foam plate forming the bottom of the recess has a recess extending from the rear edge of the plate, the width of which corresponds to the width of the angled plate section and the depth of which is less than the depth of the angled plate section, so that the underside of the angled plate section rests on the rigid foam plate arranged below it.

[0015] According to one embodiment of the present invention, the kit comprises one or more wall brackets for attaching the washbasin to a wall, forming at least two forward-projecting arms, wherein a central rigid foam panel is provided with at least two parallel, elongated recesses extending forward from the rear edge of the panel to receive the arms. Such an embodiment facilitates simple final assembly of the washbasin.

[0016] Preferably, at least the uppermost and the lowermost rigid foam boards each have a rigid foam core, waterproof layers arranged on both sides of the rigid foam core, and adhesion-promoting layers positioned on the opposite outer surfaces. Building boards constructed in this way are already commercially available. The applicant, for example, markets such a building board under the product name Schlüter KERDI-Board.

[0017] Furthermore, the present invention provides a washbasin to solve the aforementioned problem, characterized in that it is manufactured using a kit according to the invention.

[0018] Further features and advantages of the present invention will become clear with reference to the accompanying drawing in the following description. This drawing shows / shows Figure 1 is a perspective view of a washbasin according to an embodiment of the present invention; Figure 2 is an exploded view of the washbasin as described in Figure 1. Figure 1 depicted washbasin; Figure 3 an enlarged view of the in Figure 2 the section marked with reference numeral III; Figure 4 an enlarged view of the section shown in Figure 2 the section marked with reference numeral IV; and Figure 5, a sectional view of the section shown in Figure 1 depicted washbasin.

[0019] The same reference numbers refer to identical or similar components.

[0020] The figures show a washbasin 1 according to an embodiment of the present invention and a kit 2 for its manufacture. The washbasin 1 comprises a recess 19 on its upper surface with a width B and a depth T. The kit 2 for manufacturing the washbasin 1 comprises as its main components a base body 3, which forms the actual basin, two wall brackets 5, each having a blade 4, designed for attaching the washbasin 1 to a wall of a room, a drainage device 6, and two sealing membrane elements 7.

[0021] The base body 3 is primarily made of rigid foam, more precisely from a plurality of cut rigid foam sheets 8, 9, 10, and 11, which are arranged one above the other and firmly bonded together. Extruded polystyrene rigid foam (XPS) is preferred, although other rigid foams are also possible. The individual rigid foam sheets 8, 9, 10, and 11, which in this case each have a uniform thickness s, generally have a substantially rectangular shape. However, it should be clear that other shapes are also possible, for example, a square shape, a shape with rounded edges, a freeform shape, or the like, whereby the rear edge of each of the rigid foam sheets 8, 9, 10, and 11 should be substantially straight to allow for attachment to a flat wall.

[0022] The bottommost rigid foam board 8 has a rigid foam core 12 coated on both sides with a composite layer, which in this case comprises an adhesion promoter layer 14, a waterproof layer 13, and another adhesion promoter layer 14. Plastic films, such as polyethylene films, are preferred as the waterproof layers 13. The adhesion promoter layers 14 are designed as a nonwoven fabric. Alternatively, a woven fabric layer, for example, can also serve as the adhesion promoter layer 14. The board thickness s8 is in the range of 25 to 35 mm, but is generally freely selectable. A drainage opening 15 is formed in the rear area near the rear edge of the board, the shape of which is adapted to the shape of a drain 16 of the drainage device 6.The underside of the bottommost rigid foam board 8 has a continuous groove 17 extending essentially parallel to the front edge of the board, into which a light source, for example in the form of an LED strip or the like, can be inserted. It should be clear that the groove 17 can, of course, also be omitted.

[0023] The rigid foam board 9 arranged above this consists of a hard core 12. Alternatively, it can also be provided with waterproof layers 13 and adhesion-promoting layers 14, analogous to the lowermost rigid foam board 8. The rigid foam board 9 has a central rectangular recess 18, the width of which corresponds to the width B of an upper recess 19 of the washbasin 1. The depth t, however, is slightly less than the depth T of the recess 19. Furthermore, the rigid foam board 9 includes, on both sides of the central recess 18, recesses 20 for mounting brackets, which extend parallel to each other from the rear edge of the board to the front and are adapted to the dimensions of the brackets 4 of the wall supports 5. The board thickness s9 is 25 mm, and the thickness s should correspond to the height of the brackets 4 to ensure a secure hold.

[0024] The next rigid foam board 10, whose basic structure can correspond to that of the bottom or second-bottom rigid foam board 8, 9, also has a central, rectangular recess 21, the width b10 and depth t10 of which essentially correspond to the width B and depth T of the recess 19. The board thickness s10 is preferably in the range of 20 to 25 mm.

[0025] The uppermost rigid foam board 11, whose basic structure corresponds to that of the lowermost rigid foam board 8, has a downwardly angled board section 22, the width b11 and depth t11 of which essentially correspond to those of the recess 21. A front section 23 of the angled board section forms the slope of the bottom of the depression 19, and a rear section 24 forms an insertion area for the drainage device 6. For this purpose, the rear section 24 is also provided with a recess 25. The board thickness s10 is 5 mm.

[0026] The wall brackets 5, which are preferably made of metal, each have a plate-shaped mounting section 26 in addition to the blades 4. The blades 4 project from this mounting section, and each mounting section is provided with four holes 27 for screws. It should be clear that instead of two wall brackets 5, a single wall bracket with two blades can also be used.

[0027] The drainage device 6 is designed as a linear drainage system and has a sealing strip 28 along its front and upper rear edges. The sealing strips 28 are preferably each made of a layered structure which, viewed from top to bottom, comprises an adhesive layer 14, in particular made of fabric or nonwoven material, a waterproof layer 13, in particular made of plastic film, and another adhesive layer 14.

[0028] The pre-cut and pre-formed sealing membrane elements 7 are used to line the side walls of the recess 19 and are shaped accordingly. Each sealing membrane element 7 comprises overlapping sections 29 for covering the base body areas located adjacent to the side walls of the recess 19 and a sealing membrane section 30 facing the rear of the base body 3, specifically flush with the rear of the base body 3, which serves as a transition to a wall seal. The basic structure of the sealing membrane elements 7 corresponds to the structure of the sealing strips 28 of the drainage system.

[0029] To assemble the washbasin 1, the two lower rigid foam panels 8 and 9 are first positioned flush on top of each other and attached to one another, for example, by gluing them together. In a second step, the third rigid foam panel 10 is positioned on top of the second rigid foam panel 9 and attached to it. Next, the drainage device 6 is inserted from above into the drain opening 15 of the bottom rigid foam panel 8, and the front sealing strip 28 is bonded to the upper adhesive layer 14 of the bottom rigid foam panel 8, creating a seal. Finally, the top rigid foam panel 11 is placed on top of the third rigid foam panel 10 and attached to it.The plate section 22 of the uppermost rigid foam plate 11 is pressed downwards until it rests on the edge of the rigid foam plate 9 below, designated by reference numeral 31. The underside of the rear area 24 of plate section 22 is then bonded to the upper adhesive layer 14 of the lowermost rigid foam plate 8. Finally, the sealing film elements 7 are bonded to the side walls of the recess 19.

[0030] The assembly thus produced can now be slid onto the swords 4 of the wall brackets 5 attached to a room wall. The surfaces of the base body 3 can then be filled with a filler or covered with tiles. To improve the external appearance, a light fixture, in particular an LED strip, can be inserted into the groove 17.

[0031] It should be clear that the embodiment described above serves only as an example and is not intended to be restrictive. Rather, changes and modifications are possible without leaving the scope of protection defined by the accompanying claims. List of reference symbols

[0032] 1 Washbasin 2 Kit 3 Base body 4 Sword 5 Wall bracket 6 Drainage device 7 Sealing foil element 8 Rigid foam board 9 Rigid foam board 10 Rigid foam board 11 Rigid foam board 12 Rigid foam core 13 Waterproof layer 14 Bonding layer 15 Drain opening 16 Drain 17 Groove 18 Recess 19 Recess 20 Sword mounting recesses 21 Recess 22 Board section 23 Front area 24 Rear area 25 Recess 26 Mounting section 27 Hole 28 Sealing tape 29 Overlap section 30 Sealing foil section 31 Edge s Board thickness b Width B Width t Depth T Depth

Claims

1. A kit (2) for the manufacture of a washbasin (1), comprising a base body (3) with a top recess (19), the bottom of which forms a slope in the direction of a drainage opening (15) formed in the recess (19), wherein the base body (3) comprises hard foam, comprises several surfaces and is provided with a waterproof layer (13) at least on its upwardly facing surfaces, on which in turn, in particular directly, an adhesion-promoting layer (14) is arranged, which promotes adhesion of thin-bed mortar or filler material, in particular concrete filler, the base body having a plurality of cut-to-size rigid foam panels (8, 9, 10, 11), which are arranged one above the other and are firmly bonded to one another.

2. Kit (2) according to claim 1, characterized in that the waterproof layer (13) is a plastic film.

3. Kit (2) according to claim 1 or 2, characterized in that the adhesion-promoting layer (14) is a fleece or fabric.

4. Kit (2) according to one of the preceding claims, characterized in that an adhesion-promoting layer (14) is arranged directly below and above the waterproof layer (13).

5. Kit (2) according to one of the preceding claims, characterized in that the bottom of the recess (19) is formed by a downwardly angled panel section (22) of an upper rigid foam panel (11), in particular the uppermost rigid foam panel.

6. Kit (2) according to claim 5, characterized in that at least the side walls of the recess (19) are covered with, in particular, cut-to-size and preformed sealing film elements (7) which are provided with an adhesion-promoting layer (14) at least on their outwardly facing surface, in particular on both surfaces, the sealing film elements (7) each preferably having a sealing film section (30) facing the rear side of the base body (3) and, in particular, terminating flush with the rear side of the base body (3).

7. Kit (2) according to claim 5 or 6, characterized in that the rigid foam panel (11) forming the bottom of the recess (19) has a sheet thickness (s 11) in the range from 2 to 10 mm, in particular in the range from 4 to 7 mm.

8. Kit (2) according to any one of claims 5 to 7, characterized in that immediately below the rigid foam panel (11) forming the bottom of the recess (19) is arranged a rigid foam panel (10) which has a greater sheet thickness (s 10) than the rigid foam panel (11) forming the bottom of the recess (19), in particular a sheet thickness (s 10) in the range from 15 to 35 mm, more preferably in the range from 20 to 25 mm, wherein the rigid foam panel (10) arranged below the rigid foam panel (11) forming the bottom of the recess (19) has below the angled panel section (22) a recess (21) extending from the rear edge of the panel, the width (b10) of which recess corresponds to the width (b11) of the angled panel section (22) and the depth (t10) of which recess corresponds to the depth (t11) of the angled panel section (22).

9. Kit (2) according to claim 8, characterized in that a rigid foam panel (9) arranged below that rigid foam panel (10) which is arranged below the rigid foam panel (11) forming the bottom of the recess (19) has a recess extending from the rear edge (31) of the panel, the width (b9) of which corresponds to the width (b11) of the angled panel section (22), and the depth (t9) of which is less than the depth (t11) of the angled panel section (22), so that the underside of the angled panel section (22) rests on the hard foam panel (8) arranged below it.

10. Kit (2) according to one of the preceding claims, characterized in that it has one or more wall mounting brackets (5) for fastening the washbasin (1) to a wall, which wall mounting brackets (5) form at least two forwardly projecting swords (4), and in that a central rigid foam panel (9) is provided with at least two parallel, elongated sword-receiving recesses (20) extending forwardly from the rear panel edge.

11. Kit (2) according to one of the preceding claims, characterized in that it has a drainage device (6), in particular in the form of a line drainage, which is provided with at least one sealing sleeve or with a plurality of sealing tapes (28) and has a drain (16) which is designed for insertion into the drain opening (15), the sealing sleeve or the sealing tapes (28) preferably being provided with an adhesion-promoting layer (14) on their outwardly facing surfaces.

12. Kit (2) according to one of the preceding claims, characterized in that at least the uppermost (11) and the lowermost rigid foam panel (8) each have a rigid foam core (12), waterproof layers (13) arranged on both sides of the rigid foam core (12) and adhesion-promoting layers (14) positioned on the opposite outer sides.

13. Washbasin, characterized in that it is manufactured with a kit (2) according to one of the preceding claims.

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